Head wearable devices and methods

ABSTRACT

A head wearable device includes a headpiece, a housing attached to the headpiece, a luminaire attached to the headpiece, the luminaire including a luminaire housing and at least one light source located within the luminaire housing, a duct system connecting the luminaire to the housing, a ball joint rotatably connecting the duct system to the luminaire, and an air moving device configured to induce a cooling air flow through an inlet in the luminaire housing, through the heatsink, through the ball joint, through the duct system, and out of an exhaust in the housing attached to of the headpiece.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to both U.S.Provisional Patent Application Ser. No. 62/741,385, filed on Oct. 4,2018, and U.S. Provisional Patent Application Ser. No. 62/741,636, filedon Oct. 5, 2018, the disclosures of which are incorporated by referenceherein in their entireties.

TECHNICAL FIELD

The present disclosure relates generally to devices to be adjustablyworn on a human head to provide supplemental light for surgical andmedical procedures. Specifically, the present disclosure relates tolight emitting diode (“LED”) based surgical headlight systems.

BACKGROUND

Existing surgical headlights require a significant amount of light toprovide sufficient illumination for the surgeon during a typical case.Surgical headlights are also preferably lightweight so that neck andhead fatigue of the surgeon is minimized. LEDs are semiconductor devicesthat emit light by application of electrical power (watts). LEDs are afeasible light source for a surgical headlight luminaire. However, theproblem is that LEDs generate heat. One of the major challenges LEDspose in many applications is removing the heat from the LED. Excess heatmust be removed so that the semiconductor junction temperature does notexceed recommended maximum temperature. In addition, as the junctiontemperature of the LED rises, the efficiency also drops. LED lightoutput is limited by its maximum heat junction temperature, so toincrease light output without damaging the LED or reducing its operatingefficiency, heat must be transferred quickly and efficiently.

There remains a need for LED surgical headlights which allow efficienttransfer of heat energy from the LED so that the LED is sufficientlycooled and retains its light output performance and reliability.

Furthermore, surgical headlights are worn by healthcare professionals toprovide illumination to aid visualization during surgical, diagnostic,or therapeutic procedures. Headlight devices typically include aheadband, a luminaire, and other components and accessories, which couldcause discomfort or neck and head fatigue in the wearer, particularlywhen worn in a long procedure. Thus, there remains a need for surgicalheadlight devices and systems that provide enhanced comfort when worn bya wearer (e.g., a surgeon) for an extended period of time.

SUMMARY

It is an object of the present disclosure to provide a head wearabledevice comprising a headpiece; a housing on a top surface of theheadpiece; a luminaire attached to the headpiece, the luminairecomprising a luminaire housing and at least one light source thermallyconnected to a heatsink, the at least one light source and the heatsinkbeing located within the luminaire housing; a duct system connectedbetween the luminaire and the housing; a ball joint rotatably connectingthe duct system to the luminaire; an air moving device locatedconfigured to induce a cooling air flow through an inlet formed in theluminaire housing, through the heatsink, through the ball joint, throughthe duct system, and out of an exhaust formed in the housing on the topsurface of the headpiece; and a controller configured to monitor atemperature of the at least one light source and to modulate anoperational setting of the air moving device to maintain the temperatureof the at least one light source within a predetermined operating range.

It is a further object of the present disclosure to provide a headwearable device comprising: a headpiece comprising a headband comprisinga top strap and at least two lateral straps; and an occipital basketcomprising a strap, the occipital basket being attached to the headbandby at least one lateral extension strap pivotably attached by a hinge toa distal end of each respective lateral strap of the headband; a firsthousing attached to an outer surface of the top strap of the headband; adepth adjuster attached to the first housing, the depth adjustercomprising a first gear rotatably fixed to a first knob; herein thestrap of the occipital basket comprises a slot with a plurality of teethformed around a longitudinal edge of the slot; wherein the first gear iscaptively held within the slot and engages with the plurality of teeth;wherein a rotary movement of the first gear causes a longitudinalmovement of the strap of the occipital basket to change a distancebetween the occipital basket and the first housing; wherein a depth ofthe headpiece changes when the distance between the occipital basket andthe first housing changes, or increases or decreases; and wherein thestrap comprises a first visual index comprising a first plurality ofsequential characters, each of which correspond to one of a plurality ofpredetermined depth settings of the headpiece; and a second housingattached to an outer surface of the occipital basket; a circumferentialadjuster at an outer surface of the occipital basket, thecircumferential adjuster comprising a second gear rotatably fixed to asecond knob; wherein the lateral extension straps each comprise a slotwith a plurality of teeth formed around a longitudinal edge of the slot;wherein the second gear is captively held within the slot of eachlateral extension strap and engages with the plurality of teeth of eachof the lateral extension straps; wherein a rotary movement of the secondgear causes a longitudinal movement of the lateral extension straps tochange a circumference of the headpiece; and wherein at least one of thelateral extension straps comprises a second visual index comprising asecond plurality of sequential characters, each of which correspond toone of a plurality of predetermined circumferential settings of theheadpiece; wherein the lateral extension straps rotate about the hinge,relative to the lateral straps as the depth of the headpiece changes.

Still another object of the present disclosure is to provide a method ofadjusting a size of a headpiece of a head wearable device to a head sizeof a wearer, the headpiece comprising a headband and an occipitalbasket. The method comprises attaching a first housing to an externalsurface of a top strap of the headband; inserting a strap of theoccipital basket at least partially into the first housing; engaging afirst gear with a plurality of teeth formed in a slot, which islongitudinally oriented along a length of the strap of the occipitalbasket; turning a first knob, which is rotationally locked to the firstgear, to adjust a depth of the headpiece; attaching a second housing toan external surface of the occipital basket; inserting an end of atleast two lateral extension straps into the second housing, with the endof a first lateral extension strap being inserted from an opposite endof the housing from the end of a second lateral extension strap, whereinthe two lateral extension straps are hingedly attached to lateral strapsof the headband to define a circumference of the headpiece; engaging asecond gear with a plurality of teeth formed in a slot of each of thelateral extension straps such that the second gear is engaged with bothof the lateral extension straps; and turning a second knob, which isrotationally locked to the second gear, to adjust a circumference of theheadpiece.

In another object of the present disclosure, headlight devices with apadding system are provided. Such headlight devices comprise a headbandhaving a rear portion, two side portions, and a top portion, each ofwhich have a respective inner surface; a padding system comprising arear pad, which is attached to the inner surface of the rear portion ofthe headband; a side pad attached to the inner surfaces of the two sideportions of the headband; a top pad attached to the inner surface of thetop portion of the headband; and, optionally, a brow pad attached to theinner surface of the headband at an intersection of the top portion andthe two side portions; wherein at least one of the rear pad and the browpad comprises a first layer of a first cushioning material having afirst durometer, and a second layer of a second cushioning materialhaving a second durometer that is harder than the first durometer.

According to some embodiments of the present subject matter, the firstcushioning material is silicone foam having a first durometer, and thesecond cushioning material is silicone foam having a second durometerthat is harder than the first durometer; the second layer of the secondcushioning material is closer than the first layer of the firstcushioning material to the inner surface of the headband.

According to further embodiments of the present subject matter, thefirst layer of the first cushioning material and the second layer of thesecond cushioning material are each perforated; the majority of theperforations in the first layer of the first cushioning material may begenerally circular, and the majority of the perforations in the secondlayer of the second cushioning material may be in a shape other thancircular. For example, the perforations in the second layer of thesecond cushioning material are generally square or rectangular, orgenerally in a grid-like pattern.

In an aspect of the present disclosure, the second layer of the secondcushioning material has more open space on its upper or lower surfacedue to perforations than the first layer of the first cushioningmaterial. In another aspect of the present disclosure, the total volumeof cavity due to perforations in the second layer of the secondcushioning material is higher than the total volume of cavity in thefirst layer of the first cushioning material.

In additional embodiments of the present subject matter, the rear padhas an inner surface in contact with a wearer and an outer surfaceattached to the inner surface of the rear portion of the headband, andthe rear pad comprises a recess on its inner surface; at least one ofthe top pad and the side pad may comprises urethane foam and formssegments.

It is another object of the present disclosure to provide a headlightdevice comprising a headband for encircling the head of a wearer; apadding system comprising a pad removably attached to at least a portionof the headband; wherein the pad comprises a first layer of a firstcushioning material having a first durometer, and a second layer of asecond cushioning material having a second durometer that is harder thanthe first durometer; and wherein the first layer is perforated in afirst perforation pattern, and the second layer is perforated in asecond perforation pattern that differs from the first perforationpattern.

In some embodiments, the perforations in the first layer are generallyin a first perforation shape and the perforations in the second layerare generally in a second perforation shape that differs from the firstperforation shape. The perforation patterns can be chosen taking intoconsideration the softness and density of each layer specific to thecushioning material used. Punching holes or otherwise creatingperforation or cavity in the cushioning material reduces the weight ofthe padding and thus the stress on the wearer, but the removal ofcushioning material may reduce the support that the layer can provide.The perforations in the layers of cushioning material also improve heatdissipation and air-flow. Perforation patterns are selected to achieve adesired level of support and comfort.

According to some embodiments of the present subject matter, a headlightdevice is provided, the headlight device comprising: a headband forencircling the head of a wearer; a padding system comprising a rear padremovably attached to at least a portion of the headband; wherein therear pad comprises a first layer of a first cushioning material having afirst durometer, and a second layer of a second cushioning materialhaving a second durometer that is different from the first durometer;wherein the first layer is perforated in a first perforation pattern,and the second layer is perforated in a second perforation pattern thatdiffers from the first perforation pattern; wherein the first layercomprises an inner surface in contact with a wearer; wherein the secondlayer comprises an outer surface attached to the inner surface of therear portion of the headband; and wherein the rear pad comprises arecess on an inner surface thereof.

Although the embodiments of headlight devices are shown herein, thefeatures of the padding systems disclosed herein can be applied to otherhead wearable devices. Other features and advantages of the presentsubject matter will become more apparent from the following detaileddescription of the subject matter, when taken in conjunction with theaccompanying example drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter is setforth more in the remainder of the specification, including reference tothe accompanying, example figures, in which:

FIGS. 1-7 are respective directional perspective views of an embodimentof the head wearable device, in accordance with the disclosure herein;

FIGS. 8 and 9A are partial exploded views of the head wearable device ofFIGS. 1-7, in accordance with the disclosure herein;

FIG. 9B is a partial rear assembly view of the front headstrap of thehead wearable device of FIGS. 1-7, in accordance with the disclosureherein;

FIGS. 10-12 show various aspects of the thermal management features ofthe head wearable device of FIGS. 1-7, in accordance with the disclosureherein;

FIGS. 13-15 show internal views of one of the adjustment devices of thehead wearable device of FIGS. 1-7, in accordance with the disclosureherein;

FIG. 16 is a view of the head wearable device of FIGS. 1-7 showing thepadding arranged therein, in accordance with the disclosure herein;

FIG. 17 is an assembly view of the head wearable device of FIGS. 1-7with the padding omitted, in accordance with the disclosure herein;

FIGS. 18 and 19 are partial exploded views to show the adjustmentfeatures of the head wearable device of FIGS. 1-7, in accordance withthe disclosure herein;

FIG. 20 is an exterior view of a rear pad of the padding system shown inthe head wearable device of FIGS. 1-7, in accordance with the disclosureherein;

FIG. 21 is a side view of an example embodiment of the cushioningmaterials in the rear pad of FIG. 20, in accordance with the disclosureherein;

FIG. 22 is a plan view of an example embodiment of the first layer ofthe first cushioning material in the rear pad shown in FIGS. 20 and 21,in accordance with the disclosure herein;

FIG. 23 is a plan view of an example embodiment of the second layer ofthe second cushioning material in the rear pad shown in FIGS. 20 and 21,in accordance with the disclosure herein;

FIG. 24 is a plan front view of a rear pad cover for the rear pad shownin FIGS. 20 and 21, in accordance with the disclosure herein;

FIG. 25 is a plan rear view of the rear pad cover shown in FIG. 24, inaccordance with the disclosure herein;

FIG. 26 is an assembly view of the panels of the rear pad cover shown inFIGS. 24 and 25, in accordance with the disclosure herein;

FIG. 27 is a plan view of an example embodiment of a first layer of afirst cushioning material of a front pad of the head wearable deviceshown in FIGS. 1-7, in accordance with the disclosure herein;

FIG. 28 is a plan view of an example embodiment of a second layer of asecond cushioning material in a front pad of the head wearable deviceshown in FIGS. 1-7, in accordance with the disclosure herein;

FIG. 29 is a top view of an example embodiment of a side pad of the headwearable device shown in FIGS. 1-7, in accordance with the disclosureherein;

FIG. 30 is a side view of the side pad of FIG. 29, in accordance withthe disclosure herein;

FIG. 31 is a top view of an example embodiment of a top pad of the headwearable device shown in FIGS. 1-7, in accordance with the disclosureherein;

FIG. 32 is a side view of the top pad of FIG. 31, in accordance with thedisclosure herein; and

FIG. 33 is a side view of the embodiment of the head wearable deviceshown in FIGS. 1-7, showing example placement of the padding relative tothe sutures formed in a human skull.

DETAILED DESCRIPTION

Unless otherwise defined, terms used herein should be construed to havethe same meaning as commonly understood by one of ordinary skill in theart to which this subject matter belongs. It will be further understoodthat terms used herein should be interpreted as having a meaning that isconsistent with the respective meaning in the context of thisspecification and the relevant art, and should not be interpreted in anidealized or overly formal sense unless expressly so defined herein.

Aspects of the subject matter are described herein with reference tosectional, perspective, elevation, and/or plan view illustrations thatare schematic illustrations of idealized aspects of the subject matter.Variations from the shapes of the illustrations as a result, forexample, of manufacturing techniques and/or tolerances, are to beexpected, such that aspects of the subject matter should not beconstrued as limited to particular shapes illustrated herein. Thissubject matter can be embodied in different forms and should not beconstrued as limited to the specific aspects or embodiments set forthherein. In the drawings, the size and relative sizes of layers andregions can be exaggerated for clarity.

Unless the absence of one or more elements is specifically recited, theterms “comprising”, “including”, and “having” as used herein should beinterpreted as open-ended terms that do not preclude the presence of oneor more elements. Like numbers refer to like elements throughout thisdescription.

It will be understood that when an element is referred to as being “on”another element, it can be directly on the other element or interveningelements can be present. Moreover, relative terms such as “on”, “above”,“upper”, “top”, “lower”, or “bottom” are used herein to describe onestructure's or portion's relationship to another structure or portion asillustrated in the figures. It will be understood that relative termssuch as “on”, “above”, “upper”, “top”, “lower” or “bottom” are intendedto encompass different orientations of the apparatus in addition to theorientation depicted in the figures. For example, if the apparatus inthe figures is turned over, structure or portion described as “above”other structures or portions would now be oriented “below” the otherstructures or portions.

The term “substrate” or “submount” as used herein in connection withlighting apparatuses refers to a mounting member or element on which, inwhich, or over which, multiple solid state light emitters (e.g., LEDs)can be arranged, supported, and/or mounted. A substrate can be, e.g., acomponent substrate, a chip substrate (e.g., a LED substrate), or asub-panel substrate. Example substrates useful with lighting apparatusesas described herein can, for example, comprise printed circuit boards(PCBs) and/or related components (e.g., including but not limited tometal core printed circuit boards (MCPCBs), flexible circuit boards,dielectric laminates, ceramic based substrates, and the like), ceramicboards having FR4 and/or electrical traces arranged on one or multiplesurfaces thereof, high reflectivity ceramics (e.g., alumina) supportpanels, and/or mounting elements of various materials and conformationsarranged to receive, support, and/or conduct electrical power to solidstate emitters. Electrical traces described herein provide electricalpower to the emitters for electrically activating and illuminating theemitters. Electrical traces may be visible and/or covered via areflective covering, such as a solder mask material, Ag, or othersuitable reflector.

FIGS. 1-7 show several perspective views of a head wearable device,generally designated 1. In the embodiment shown, the head wearabledevice 1 comprises an adjustable headpiece comprising a headband,generally designated 100, which has a top strap 110 and at least twolateral straps 120A/120B, and an occipital basket 150 attached to (e.g.,removably, fixedly, and/or integrally) the headband 100; a luminaire,generally designated 200, movably attached at the front of the headband100, a duct system, generally designated 300, to direct exhaust air fromthe luminaire 200 to a hot air exhaust 420 formed in the upper housing,generally designated 400, that is attached to the top strap 110 of thehead wearable device 1; rear adjustment straps 130A/130B; a depthadjuster, generally designated 450, and a headband adjuster, generallydesignated 700, that are for adjusting the size of the headband 100 tothe size of a wearer's head; a holster 600 with a battery pack andcontroller that is in electrical communication, via power cord 602, withthe luminaire 200 and an air moving device (see 332, FIG. 8) associatedwith the duct system 300; and a padding system, generally designated500, installed on at least some of the inner surfaces of the headband100 and occipital basket 150. As shown, the lateral straps 120A/120B,together with the rear adjustment straps 130A/130B form a thin, flexibleplastic ring of an approximately elliptical shape for fittinghorizontally on the head of a wearer. The upper housing 400 can extendfrom the front to the rear (e.g., the occipital basket 150) of theheadband 100, extend between the lateral straps 120A/120B of theheadband 100, or extend between any two points on the ring. Two or moreof these portions may form an integral piece, or operably or adjustablyconnected to each other. Headband may be constructed with more or fewerportions or straps than the embodiment shown and may take any shape. Theheadbands may cover more or less surface of the wearer's head than theembodiment as shown. While the headpiece is shown in this embodiment ascomprising the headband 100 and the occipital basket 150, the headpiecemay take any shape and may have a substantially continuous outer coverthat is either adjustable to a wearer's head size or of fixeddimensions. Similarly, an outer shell may be provided around theheadpiece, as needed based on the environment in which the head wearabledevice is to be worn.

In the embodiment shown, the headband 100 comprising the top strap 110and lateral straps 120A/120B is integrally formed from a single piece.An example of this portion of the headband 100 is shown in FIGS. 9A and9B, with the top strap 110 and lateral straps 120A/120B being shown in asubstantially planar (i.e., flat), unformed, configuration. The topstrap 110 has upper housing 400 affixed thereto, into which the topstrap 152 from the occipital basket 150 is inserted to connect the topstrap 110 to the occipital basket 150. The upper housing 400 has anouter shell 410, which has a slot, generally designated 412, formed at arear of the outer shell 410, into which slot 412 the strap 152 of theoccipital basket 150 is inserted to adjust the depth of the headwearable device 1. The strap 152 of the occipital basket 150 has a slot(see 154, FIGS. 13-15) formed along the length thereof, the length ofthe slot 154 defining a maximum amount of adjustment of the depth of thehead wearable device 1. As can be seen in greater detail in FIGS. 13-15,the slot 154 of the strap 152 has, on at least one side thereof, aplurality of teeth 156 that are configured to interface with, and bemoved by, a gear 470 that is rotatably mounted within the upper housing400 in the form of a rack-and-pinion arrangement. As such, a rotation ofthe top adjustment knob 460 and, accordingly, the top adjustment gear470, causes the strap 152 of the occipital basket 150 to be lengthenedor shortened relative to the upper housing 400 as the gear 470 draws thestrap 152 into, or pushes the strap 152 out of, the upper housing 400.Due to the rack-and-pinion arrangement, precise size adjustments to thedepth of the head wearable device 1 are contemplated. As such, aplurality of indexing marks, generally designated 157, are provided inan externally visible location on the strap 152 of the occipital basket150 so that the depth of the head wearable device 1 may be easily andrepeatably adjusted to a given value for a plurality of wearers of thehead wearable device 1.

The headband 100 is further connected to the occipital basket 150 bylateral extension straps 130A/130B, which are rotatably coupled to thelateral straps 120A/120B, respectively, at respective hinges, generallydesignated 140A/140B, which in this embodiment are circular hinges. Eachof the lateral extension straps 130A/130B wraps behind the occipitalbasket 150 and is inserted within a housing of the headband adjuster,generally designated 700, which is shown on the rear external surface ofthe occipital basket 150. As can be seen in FIGS. 9A and 9B, the lateralextension straps 130A/130B have a slot 132A/132B formed along the lengththereof, respectively, the length of the slot 132A/132B defining amaximum amount of adjustment of the circumference of the head wearabledevice 1. The slot 132A/132B of each lateral extension strap 130A/130Bhas, on at least one side thereof, a plurality of teeth 134A/134B thatare configured to interface with, and be moved by, a gear (see 730, FIG.19) that is rotatably mounted within the housing of the headbandadjuster 700 in the form of a rack-and-pinion arrangement. The pluralityof teeth 134A on a first of the lateral extension straps 130A are on anopposite side of the slot 132A from the plurality of teeth 134B formedin the slot 132B of the second lateral extension strap 130B, such that arotating motion of the occipital basket adjustment gear 730 causes asimultaneous expansion or contraction, depending on the direction inwhich the knob 740 is rotated, of the headband 100 to correspondinglyincrease or decrease lateral circumference of the head wearable device1. Due to the rack-and-pinion arrangement, precise size adjustments ofthe head wearable device 1 are contemplated. As such, a plurality ofindexing marks, generally designated 137, are provided in an externallyvisible location on one or more of the lateral extension straps130A/130B so that the head wearable device 1 may be easily andrepeatably adjusted to a given size for a plurality of wearers of thehead wearable device 1. The slots 132A/132B are shown as being closed atboth ends thereof to prevent the lateral extension straps 130A/130B frombecoming disengaged from the headband adjuster 700. As such, the lateralextension straps 130A/130B are captively held within the headbandadjuster 700 when worn by a wearer.

The hinges 140A/140B connecting the lateral straps 120A/120B of theheadband 100 to the lateral extension straps 130A/130B are configured topivot about an axis defined through the center of each respective hinge140A/140B. Any type of hinge may be used and, in fact, the lateralextension straps 130A/130B may be integrally formed with the lateralstraps 120A/120B of the headband 100. However, it is advantageous to usethe circular hinges 140A/140B shown because, as the strap 152 is drawninto or pushed out from the upper housing 400 on the headband 100 toalter a depth of the head wearable device 1, the position of theoccipital basket 150 changes at least vertically, relative to thelateral straps 120A/120B, such that the angle between the lateral straps120A/120B and the lateral extension straps lateral extension straps130A/130B at the hinges 140A/140B can be altered without deforming thelateral extension straps 130A/130B that might cause any distortions ordeformations thereof in the region of the slots 132A/132B, therebypreventing binding of the lateral extension straps 130A/130B within thehousing of the headband adjuster 700.

A padding system 500 is attached to the inner surfaces of the headwearable device 1, including the inner surfaces of the headband 100 andthe occipital basket 150 where contact would otherwise occur with thehead of a wearer of the head wearable device 1. While any suitable typeand configuration of padding may be utilized for the padding system 500,the embodiment shown has padding segments that are attached to the innersurfaces of the headband 100 and the occipital basket 150. The paddingsegments may be formed from any suitable material having a suitabledegree of padding to provide a desired amount of comfort for a wearerduring extended wearing times (e.g., on the order of multiple hours).The padding system comprises a rear pad 550, side pads 520/530, and atop pad 540 attached to the corresponding inner surfaces of theoccipital basket 150, the lateral straps 120A/120B, and the top strap110 of the head wearable device 1, respectively. The padding system 500may further comprise a brow pad 510 attached to the inner surface of theheadband at or about an intersection of the top strap 110 and thelateral straps 120A/120B. Each of the padding segments 510, 520, 530,540, and 550 described herein can be portions of a large integral padand do not need to be separate pads.

The padding segments 510, 520, 530, 540, and 550 are attached to theheadband 100 or the occipital basket 150, respectively, by any suitableattachment type, including, for example, adhesive, interlocking snaps,mechanical interlocking tabs, and the like. The padding segments 510,520, 530, 540, and 550 may be contoured to the shape of the respectivestrap or occipital basket 150 to which the padding segment 510, 520,530, 540, and 550 is attached and may have a size less than or greaterthan a width of the strap(s) to which each such padding segment 510,520, 530, 540, and 550 is attached. As such, a brow pad is provided atthe front of the headband 100 at a position that would be against theforehead of a wearer of the head wearable device 1. This brow pad 510may extend, at least to some extent, onto the top strap 110 and the twolateral straps 120A/120B. In the embodiment shown, the strap 152 of theoccipital basket 150 and the lateral extension straps 130A/130B aredevoid of padding segments, not only because these portions are spacedapart from the surface of the wearer's head while being worn, but alsoso that mechanical interference does not occur between adjacentcomponents as the dimensions (e.g., the depth and/or the circumference)of the head wearable device 1 is adjusted. In the embodiment shown, thepadding segments 510, 520, 530, 540, and 550 can be removable forcleaning, maintenance, etc. One or more of the padding segments 510,520, 530, 540, and 550 can have a different degree of softness fromothers of the padding segments 510, 520, 530, 540, and 550. One or more(e.g., each, or all) padding segments 510, 520, 530, 540, and 550 mayhave more than two layers of cushioning material.

Referring to FIGS. 20-26, according to some embodiments of the presentdisclosure, the rear pad 550 comprises a first layer 570 of a firstcushioning material having a first durometer, and a second layer 580 ofa second cushioning material having a second durometer that is harderthan the first durometer. In an example embodiment, the first cushioningmaterial is silicone foam, and the second cushioning material is alsosilicone foam, but the silicone foam in the second layer 580 has ahigher durometer than the silicone foam in the first layer 570. Forexample, the durometer of the second layer 580 can be 5%, 10%, 25%, orup to and including 50% higher than the durometer of the first layer570. In other words, the silicone foam in the second layer 580 is harder(e.g., less compliant) than the silicone foam in the first layer 570.The second layer 580 of the second cushioning material is closer thanthe first layer 570 of the first cushioning material to the innersurface of the occipital basket 150. The harder second layer 580provides support, while the softer, conforming first layer 570 is incloser contact with the wearer and provides increased comfort to thewearer of the head wearable device 1.

Although FIG. 21 shows that the first layer 570 and the second layer 580of the respective cushioning materials have the same or similarthickness, it is contemplated that the first layer 570 can have adifferent thickness from the second layer 580. The thickness of eachlayer is preferably no more than 1 inch (in.) and, more preferably, nomore than 0.5 in., for example, about 0.25 in. In an example embodiment,the first layer 570, which is oriented towards (e.g., adjacent the headof) the wearer, is ¼″ die-cut silicone foam (for example, BISCO®BF-2000, an ultra soft silicone foam manufactured by Rogers Corporation)and the second layer 580, which is oriented towards (e.g., adjacent thesurface of) the occipital basket 150 is ¼″ die-cut silicone foam (forexample, BISCO® HT-800, a medium cellular silicone foam manufactured byRogers Corporation), which can be either open cell silicone foam orclosed cell silicone foam. In some aspects, the respective durometers ofthe silicone foam layers can be defined by compression force deflectionof the foam silicone. In some embodiments, the durometer is within arange of about (e.g., ±1%, ±2%, ±5%, ±10%, ±25%, or ±50%) 10-70 Shore A,inclusive. HT-800 silicone foam has a density, as measured according toASTM D 1056, of 22 pounds per cubic feet (Ib/ft³). BF-2000 silicone foamhas a density, as measured according to ASTM D 1056, of 10 lb/ft³. Forthe first layer 570, the die-cut silicone foam (BF 2000) can have acompression force deflection of about (e.g., ±1%, ±2%, ±5%, ±10%, ±25%,or ±50%) 1.5 pounds per square inch (psi). The compression forcedeflection is a measure of the load bearing ability of a foam materialand is the force exerted against a flat compression foot that is largerthan the specimen to be tested. The term compression force deflection isalso sometimes referred to as “compression load deflection”. Thecompression force deflection metric is measured as the force necessaryto achieve a 25% deflection according to ASTM D 1056. For the secondlayer 580, the die-cut silicone foam (for example, BISCO® HT-800) canhave a compression force deflection of within a range including, forexample, about (e.g., ±1%, ±2%, ±5%, ±10%, ±25%, or ±50%) 6-14 psi. Insome embodiments, the second layer 580 of the second cushioning material582 has more open space on its upper or lower surface due toperforations than the first layer 570 of the first cushioning material572, which has, in the embodiment shown, a surface area of about 10.617square inches (in²). In another aspect, the total surface area of thecavities formed by the perforations 584 in the second layer 580 of thesecond cushioning material 582 is higher than the total surface area ofthe cavities formed by the perforations 574 in the first layer 570 ofthe first cushioning material 572, for example, the total surface areaof the cavities in the second layer 580 is about 9.249 in².

In some embodiments, the perforation patterns can be chosen taking intoconsideration the durometer (e.g., hardness) and density of each layerspecific to the cushioning material used. The perforations in the layersof cushioning material also improve heat dissipation and air-flow. Forthe rear pad 550, the volume of the first cushioning material 572removed from the first layer 570 in forming the plurality ofperforations 574 is about 1.575 cubic inches (in³) and the volume of thesecond cushioning material 582 removed from the second layer 580 informing the plurality of perforations 584 is about 5.112 in³.

According to further embodiments of the present subject matter, thefirst layer 570 of the first cushioning material 572 and the secondlayer 580 of the second cushioning material 582 are each perforated. Asshown in FIG. 22, the first layer 570 has a first perforation patterncomprising a plurality of first perforations 574 formed therein. FIG. 23shows the second layer 580, which has a second perforation patterncomprising a plurality of second perforations 584. The first perforationpattern and the first perforations 574 differ from the secondperforation pattern and the second perforations 584. The firstperforations 574 in the first layer 570 are generally arranged in afirst perforation shape and the second perforations 584 in the secondlayer 580 are generally in a second perforation shape, which may differfrom the first perforation shape. For example, the first perforations574, or at least the majority of the first perforations 574, in thefirst layer 570 of the first cushioning material 572, are generallycircular, and the second perforations 584, or at least the majority ofthe second perforations 584, in the second layer 580 of the secondcushioning material 582 are in a shape other than circular, such asgenerally square, rectangular, and/or triangular, or generally in agrid-like pattern. The first and second perforations 574/584 are holesor apertures that pass through the thickness of the respective first andsecond cushioning materials 572/582. The first and second perforations574/584 can be created by die-cutting, piercing, boring, or any otherconventional methods.

A different perforation pattern can be a result of a higher perforationcount of the perforation of the same shape, or perforations of adifferent shape or different shapes, or a combination of the foregoing.In an aspect of the present disclosure shown in FIG. 23, the secondlayer 580 of the second cushioning material 582 has more open space onits upper or lower surface due to second perforations 584 than the firstlayer 570 of the first cushioning material 572. In another aspect of thepresent disclosure, the total volume of the cavities formed by thesecond perforations 584 in the second layer 580 of the second cushioningmaterial 582 is higher than the total volume of the cavities formed bythe first perforations 574 in the first layer 570 of first cushioningmaterial 572. The second layer 580 has a cut-out recess, generallydesignated 586, which substantially defines the size, shape, and/orcontour of the cut-out recessed region 556 of the rear pad 550, thecut-out recess 586 and the cut-out recessed region 556 having a size,shape, and/or contour that corresponds to the size, shape, and/orcontour of the cut-out 158 of the occipital basket 150.

In additional embodiments of the present subject matter, the rear pad550 has an inner surface in contact with a wearer and an outer surfaceattached to the inner surface of the rear portion of the headband, andthe rear pad 550 comprises a recess 576 formed in the first layer 570.

In each of the respective padding segments 510, 520, 530, 540, and 550,the cushioning material may be any suitable synthetic foam such assilicone foam, expanded polystyrene, polyurethane, or other types ofpolymer. In an example embodiment of the present disclosure, thecushioning material in both layers are a silicone foam, for example, thesilicon foam materials commercially available at Stockwell Elastomerics,Inc. The differences in the first and second layers 570/580 include thedurometer of the first and second cushioning materials 572/582. Anysuitable material may be used as long as the material has a similardurometer as the materials specified herein.

As shown in FIGS. 24-26, the rear pad 550 is covered by a rear pad cover552, which can be made of fabric, synthetic polymers, or other suitablematerials, such as polyethylene, nylon, glass fibers and the like. Therear pad 550 comprises a recessed area 553 formed therein, between theopposing padding lobes 554 that have, in the embodiment shown, agenerally triangular shape. The recessed area 553 is provided to relievepressure from the occipital basket 150 being secured over the rearportion of the head of a wearer, thereby accommodating accessories wornby the wearer, such as, for example, straps for the cap, loupe, orglasses and the like, without interfering with the head wearable device1 being sufficiently secured over the wearer's head and to avoidpressure that may push against the back of the wearer's head. Any shapefor the rear pad 550 is contemplated and, furthermore, the recessed area553 can be in any shape, including, as shown in FIG. 20, a generallytriangular shape. Recessed area 553 can have a reduced thicknesscompared to the thickness of the rear pad 550 overall and/or to thepadding lobes 554. In the example embodiment shown, the rear pad cover552 is able to sufficiently surround a rear pad 550 having a totalvolume of about 7.18 in³. In an example embodiment, the rear pad cover552 is made of Darlington 96630 fabric manufactured by Darlington. TheDarlington 96630 material used in the example embodiment is a 4-waystretch heavy weight tricot, 356 gsm (grams per square meter) weight,and is available in various colors. As shown in FIG. 26, the back ofrear pad cover 552 shown in FIG. 25 may be produced by layering a mainbody piece 558A, two inner overlap pieces 558B and two netting pieces558C in the order as illustrated, such that the back of the rear padcover 552 has an elastic netting pocket 564 on the outer surface of eachside flap. The rear pad cover 552 comprises a cut-out recessed region556 contoured to the shape of the occipital basket 150 and also coversthe recess 576. Regardless of the materials specified herein, it iscontemplated that at least a portion of the rear pad cover 552 may bemade from a breathable stretch material with an estimated weight withinthe range of about 300-400 gsm inclusive.

The front of the rear pad cover 552 can be fabric such as Darlingtonfabrics, 4-way stretch spandex, while the back of the rear pad cover 552can be nylon/UBL (unbroken loop) fabric 560, which is a part of ahook-and-loop fastening system, with optional snaps 562 provided to moresecurely attach the rear pad cover 552 over the rear pad 550. Othermaterials are suitable for use in the padding system 500, and can beselected depending on cleaning and comfort requirements.

The rear pad 550 can be assembled by aligning the front of rear padcover 552 shown in FIG. 24, the first layer 570 of the first cushioningmaterial shown in FIG. 22, the second layer 580 of the second cushioningmaterial shown in FIG. 23, and the back of the rear pad cover 552 shownin FIG. 25, and then sewing along the periphery of the covers. Thestretch-mesh netting pockets 564 on the back of the rear pad cover 552is made of an elastic material, such as spandex mesh, and is removablydisposed about the outer surface of the corresponding side flaps of theoccipital basket 150 to help secure the rear pad cover 552 to theoccipital basket 150. The recess in the rear pad 550 can be formed byadding stitches along the corresponding recess 576 in the first layer570 of the first cushioning material in the rear pad 550.

Referring to FIGS. 27 and 28, the brow pad 510 comprises a first layer512 of a first cushioning material having a first durometer, and asecond layer 516 of a second cushioning material having a seconddurometer that is different (e.g., harder) than the first durometer. Thefirst layer 512 is perforated in a first perforation pattern, comprisingfirst perforations 514, and the second layer 516 is perforated in asecond perforation pattern, comprising second perforations 518, whichdiffer from the first perforation pattern. In an example embodiment, thefirst layer 512 of the first cushioning material of the brow pad 510 isconfigured as a comfort layer arranged adjacent the head of the wearerand is formed from ¼″ die-cut silicone foam (BF 2000), while the secondlayer 516 of the second cushioning material is spaced apart from thehead of the wearer and is formed ¼″ die-cut silicone foam (for example,BISCO® HT-800).

Although the example embodiments of rear pad 550 and brow pad 510 bothinclude a softer, inner, first layer of cushioning material and aharder, outer, second layer of cushioning material, other layeringoptions are contemplated, depending on the cleanability and comfortstandards and the desired fit, feel, and comfort level. In someembodiments, the BISCO® silicone foams disclosed herein can be describedas being a range of materials, including extra firm (HT-840), firm(HT-820), medium (HT-800), soft (HT-870), extra soft (BF-1000), andultra soft (BF-2000). HT-840 has a compression force deflection within arange of 16-26 psi and, preferably, a compression force deflection of 22psi. HT-820 has a compression force deflection range of 12-20 psi and,preferably, a compression force deflection of 16 psi. HT-800 has acompression force deflection within a range of 6-14 psi and, preferably,a compression force deflection of 9 psi. HT-870 has a compression forcedeflection within a range of 2-7 psi and, preferably, a compressionforce deflection of 4 psi. BF-1000 has a compression force deflectionwithin a range of 1-5 psi and, preferably, a compression forcedeflection of 3 psi. BF-2000 has a compression force deflection of about1.5 psi. Some other possible combinations of generally hard, medium, andsoft layers include medium inner—medium outer, hard outer—medium inner,and soft outer—soft outer layering combinations. Any of the extra firm,firm, medium, soft, extra soft, and ultra soft materials may be combinedto form the first and second layers of padding.

Examples of such combinations for any of padding segments 510, 520, 530,540, and 550 can include a first layer comprising extra firm (having afirst durometer with a compression force deflection in a range of 16-26psi) silicone foam and a second layer comprising silicone foam of any ofthe following types: firm (having a second durometer with a compressionforce deflection in a range of 12-20 psi), medium (having a seconddurometer with a compression force deflection in a range of 6-14 psi),soft (having a second durometer with a compression force deflection in arange of 2-7 psi), extra soft (having a second durometer with acompression force deflection in a range of 1-5 psi), or ultra soft(having a second durometer with a compression force deflection of about1.5 psi).

Other examples of such combinations for any of padding segments 510,520, 530, 540, and 550 can include a first layer comprising firm (havinga first durometer with a compression force deflection in a range of12-20 psi) silicone foam and a second layer comprising silicone foam ofany of the following types: extra firm (having a second durometer with acompression force deflection in a range of 16-26 psi), medium (having asecond durometer with a compression force deflection in a range of 6-14psi), soft (having a second durometer with a compression forcedeflection in a range of 2-7 psi), extra soft (having a second durometerwith a compression force deflection in a range of 1-5 psi), or ultrasoft (having a second durometer with a compression force deflection ofabout 1.5 psi).

Another set of examples of such combinations for any of padding segments510, 520, 530, 540, and 550 can include a first layer comprising medium(having a first durometer with a compression force deflection in a rangeof 6-14 psi) silicone foam and a second layer comprising silicone foamof any of the following types: extra firm (having a second durometerwith a compression force deflection in a range of 16-26 psi), firm(having a second durometer with a compression force deflection in arange of 12-20 psi), soft (having a second durometer with a compressionforce deflection in a range of 2-7 psi), extra soft (having a seconddurometer with a compression force deflection in a range of 1-5 psi), orultra soft (having a second durometer with a compression forcedeflection of about 1.5 psi).

In still other examples, such combinations for any of padding segments510, 520, 530, 540, and 550 can include a first layer comprising soft(having a first durometer with a compression force deflection in a rangeof 2-7 psi) silicone foam and a second layer comprising silicone foam ofany of the following types: extra firm (having a second durometer with acompression force deflection in a range of 16-26 psi), firm (having asecond durometer with a compression force deflection in a range of 12-20psi), medium (having a second durometer with a compression forcedeflection in a range of 6-14 psi), extra soft (having a seconddurometer with a compression force deflection in a range of 1-5 psi), orultra soft (having a second durometer with a compression forcedeflection of about 1.5 psi).

In further examples, such combinations for any of padding segments 510,520, 530, 540, and 550 can include a first layer comprising extra soft(having a first durometer with a compression force deflection in a rangeof 1-5 psi) silicone foam and a second layer comprising silicone foam ofany of the following types: extra firm (having a second durometer with acompression force deflection in a range of 16-26 psi), firm (having asecond durometer with a compression force deflection in a range of 12-20psi), medium (having a second durometer with a compression forcedeflection in a range of 6-14 psi), soft (having a second durometer witha compression force deflection in a range of 2-7 psi), or ultra soft(having a second durometer with a compression force deflection of about1.5 psi).

In yet further examples, such combinations for any of padding segments510, 520, 530, 540, and 550 can include a first layer comprising ultrasoft (having a first durometer with a compression force deflection ofabout 1.5 psi) silicone foam and a second layer comprising silicone foamof any of the following types: extra firm (having a second durometerwith a compression force deflection in a range of 16-26 psi), firm(having a second durometer with a compression force deflection in arange of 12-20 psi), medium (having a second durometer with acompression force deflection in a range of 6-14 psi), soft (having asecond durometer with a compression force deflection in a range of 2-7psi), or extra soft (having a second durometer with a compression forcedeflection in a range of 1-5 psi).

In some embodiments, the second layer 516 of the second cushioningmaterial has more open space on its upper or lower surface due toperforations than the first layer 512 of the first cushioning material,which has, in the embodiment shown, a surface area of about 7.712 in².In another aspect, the total surface area of the cavities formed by theperforations 518 in the second layer 516 of the second cushioningmaterial is higher than the total surface area of the cavities formed bythe perforations 514 in the first layer 512 of the first cushioningmaterial, for example, the total surface area of the cavities in thesecond layer 516 is about 5.858 in².

In some embodiments, the perforation patterns can be chosen taking intoconsideration the durometer (e.g., hardness) and density of each layerspecific to the cushioning material used. The perforations in the layersof cushioning material also improve heat dissipation and air-flow. Forthe brow pad 510, the volume of the first cushioning material removedfrom the first layer 512 in forming the plurality of perforations 514 isabout 1.179 in³ and the volume of the second cushioning material removedfrom the second layer 516 in forming the plurality of perforations 518is about 3.033 in³.

The differences between the respective first and second perforationpatterns can also aid in visually deciphering the first layer 512 fromthe second layer 516. The outer layer of primarily circle die-cuts maybe laid out over the grid formed by the second perforations 518 formedin the second layer 516 to optimize air-flow between the first layer 512and the second layer 516. Additionally, a higher perforation count maybe used in the first layer 512 on the foam to increase the degree ofcompression and softness of the first compression material. The firstperforations 514 comprise round holes to provide flexibility to exploreactual hole count among the different designs, but as described abovethe first perforations 514 do not have to be circular. The actual designand perforation patterns should take into account the amount of materialremoved, not simply the shape of the die-cuts.

Referring to FIGS. 29 and 30, the top cover 522/532 of the side pads520/530 can be made of fabric, for example, Darlington 96630 fabricmanufactured by Darlington, which is a 4-way stretch Heavy Weight Tricotwith a 356 gsm weight. The pad shown here is a side pad 520/530 for oneside portion of the headband 100. The side pad 520/530 for the otherside portion of the headband 100 is a mirror image of the side pad520/530 as shown.

The rear 526/536 of the side pad 520/530 includes an attachment thatsecures the side pad 520/530 to the lateral strap 120A/120B of theheadband 100. An example of a suitable attachment includes ahook-and-loop fastener system. The side pad 520/530 is filled withopen-cell urethane foam or other suitable cushioning material to providethe desired level of support and comfort. A depression 524/534 can beformed by stitching across the side pad 520/530, thereby creating two ormore padding segments in the side pad 520/530.

Referring to FIGS. 31 and 32, like the side pad shown in FIGS. 29 and30, the top pad 540 can be made of fabric, for example, Darlington 96630fabric. In the embodiment shown, the rear 546 of the top pad 540includes a hook and loop fastener strip. Other suitable attachment typesare contemplated. The top pad 540 is filled with open-cell urethane foamor any other suitable cushioning material, and the foam can be of anysuitable thickness, for example, ¾″ urethane foam support.

Although the top pad 540 and the side pad 520/530 are described hereineach in singular form, there may be more than one top pad 540 and atleast two side pads 520/530 for the two lateral straps 120A/120B of theheadband 100. Each of these pads may have similar constructions butdifferent shapes, lengths, thickness, curvatures, and the like to adaptthe respective pad to the corresponding contour of the strap of theheadband 100 for attachment. In addition, although the respective padsare shown as segmented pieces, one or more of the padding segments maybe connected or all may be formed as an integral portion of the paddingsystem 500.

The padding segments 510, 520, 530, 540, and 550 in the padding system500 can be attached the headband 100 and the occipital basket 150 invarious ways, either permanently or removably, for example, by hook andloop fasteners, snapping members, stitching, adhesive, ties, and anyother suitable types of attachment known in the art. In an exampleembodiment, the brow, side and top pads 510, 520, 530, and 540 are allbacked with a die-cut loop material to anchor them to the headband 100.

The occipital basket 150 comprises at least one padding segment 550removably attached thereto. As shown in FIG. 16, the occipital basket150 comprises a cut-out 158, or notch, formed at the bottom edge thereofthat defines a location where a wearer's hair can exit the occipitalbasket 150 without substantially interfering with the occipital basket150 fitting securely against the rear of the wearer's head. The cut-out158 is also formed to accommodate any features of a head wearablegarment (e.g., a knot used to secure a surgical cap over the head of thewearer). In the embodiment of FIGS. 1-7, the rear pad 550 is a unitary(e.g., integral or monolithic) padding segment that is attached to theoccipital basket 150 by a retention strap 566 (see FIG. 25) and netting564 (see FIG. 25) that contain each of the lower corners of theoccipital basket 150 (e.g., on opposite sides of the cut-out) thereinand an upper strap 560 (see FIG. 25) which passes around the strap 152of the occipital basket 150 and is secured thereto by snaps 562 (seeFIG. 25) or any other suitable fastener. As shown at least in FIG. 16,the rear pad 550 on the occipital basket 150 has an outercontour/profile shape that is substantially similar to that of theoccipital basket 150 itself, including the cut-out 158. Furthermore, therear pad 550 on the occipital basket 150 comprises a cut-out recessedregion 556 to accommodate a wearer's hair style without interfering withthe head wearable device 1 being sufficiently secured over the wearer'shead and to avoid pressure that may push against the back of thewearer's head.

FIG. 33 shows an embodiment of the head wearable device 1, similar tothat shown in FIGS. 1-7, fitted on and over a human skull, generallydesignated 800, to demonstrate possible and what can be preferredplacement of the padding segments (e.g., 510, 520, 530, 540, 550)relative to skull region joinder lines or sutures, such as for examplesutures 810, 820, 830, and/or 840, that exist between adjacent skullplates of the skull 800 and are configured to be positioned on a headwithout covering or being disposed or positioned over any or asubstantial portion of the skull sutures such as sutures 810 shown. Asshown, the padding segments are spaced such that, in at least someconfigurations, the weight of the head wearable device 1 is not placedon or over the skull sutures. For example, the shape of the lateralstraps 120A/120B and the hinges 140A/140B avoid placement over, and donot contact and/or put pressure on, the squamous suture 830 and thelambdoid suture 820, while the top pad 540 does not contact at least aportion of the sagittal suture 840. As such, the side pads 520/530 ofthe lateral straps 140A/140B do not contact or apply pressure over anysuture (e.g., 810, 820, 830, and/or 840) of the skull 800 of the wearerof the head wearable device 1. In the embodiment shown, a gap, generallydesignated 542, is present between segments of the top pad 540 so thatthe top pad 540 does not contact the head of the wearer in a regioncovering or over the coronal suture 810 of the skull 800 of the wearer.Stated differently, the top pad 540 is spaced apart from the head of thewearer over one or more sutures 810 of the wearer's skull 800. As such,the top pad 540 does not contact the wearer's head at areas of thesutures 810 of the wearer's skull 800. A gap, generally designated 522,532, is present between segments of the side pads 520, 530 so that theside pads 520, 530 do not contact the head of the wearer in a regioncovering or over a suture 810 of the skull 800 of the wearer. The sidepad 520, 530 is therefore against the head but can be laterally spacedapart from the head of the wearer over one or more sutures 810 of thewearer's skull 800. As such, the side pads 520, 530 do not contact thewearer's skull at the sutures 810 of the wearer's skull 800. In someembodiments, the top pad 540 and/or the side pads 520, 530 can beadjusted positionally so that the gap 522, 532, 542 can be positionedover the suture 810 of the skull of the wearer to provide enhancedcomfort for the wearer during extended periods of use of the headwearable device 1. While FIG. 33 is a view of one side of the headwearable device 1 over a skull 800 of the wearer, the opposing view isidentical to (e.g., is a mirror image of) the side view of FIG. 36, suchthat the features shown therein and described hereinabove are presentfor both sides of the head wearable device 1 relative to the skull 800of the wearer.

The luminaire 200 comprises an external housing 210 and is attached atthe forward edge of the headband 100 by any suitable mechanical linkage,generally designated 350. In some embodiments, the mechanical linkage350 is a statically attached mounting point to which the luminaire 200is rigidly and/or pivotably attached. In the embodiment shown, themechanical linkage 350 comprises a mount that is connected to the frontof the headband 100 and linkage bars 354 that are pivotably connectedtogether by linkage rollers 356. As shown in FIG. 17, the mechanicallinkage 350 is secured to the headband 100 by mounting hardware (e.g.,screws and washers), generally designated 358, which pass through thethickness of the headband 100 at the front thereof. The mechanicallinkage 350 is provided to allow the angle of the luminaire 200 relativeto the headband 100 and the distance of the luminaire 200 from theheadband 100 to be controlled independently. The luminaire 200comprises, as is shown at least partially in FIGS. 10-12, at least oneLED 232 (e.g., any suitable light source), which can be mounted on asubstrate. Such a substrate can be affixed (e.g., rigidly) to a heatsink220 located within the luminaire housing 210 to conduct heat generatedby the at least one LED 232 into the heatsink 220. Such a substrate canhave surface-mount connection points for the LED's power and sensingelectrical needs. The substrate can be formed such that the LED 232 andthe heatsink 220 are located in opposing first and second regions of theluminaire housing 210, the first region being adjacent the lens cell andthe second region being located away from (e.g., spaced apart from) theLED 232. The substrate may be configured to allow for a straight-lineoptical cell configuration, as opposed to a bent-configuration, therebyeliminating the need for a mirror to perform the optical bend necessaryfor such configurations. In some embodiments, such a substrate can be alaminated printed circuit board (PCB) and/or comprises copper to provideenhanced thermal conductivity between the LED 232 and the heatsink 220to the substrate. The use of copper in such a substrate can beadvantageous, as copper's high thermal conductivity allows for theefficient conduction of heat from the LED 232 to the heatsink 220 fordissipation into a cooling air stream flowing into the luminaire housing210 via the inlet 212, two of which are formed on opposing sides of theluminaire housing 210. The heatsink 220 can be of any suitableconstruction, including, for example, extrusion, soldering, skiving, andthe like, and can comprise any suitably conductive material, such as,for example, aluminum or copper.

The luminaire housing 210 is connected, via a pivoting ball joint 310,to a duct 300 system. The ball joint 310 is formed of two half-members311 assembled together to form the ball joint 310 and the luminairehousing 210 is clamped around the outer lateral edges of the ball joint310 to allow the luminaire housing 210 to rotate independently of andabout the ball joint 310. The ball joint 310 is rotatable about an axisthat is perpendicular to the duct system 300, unlike known solutionsthat rotate about an axis parallel to the air flow path to avoidinducing kinks or other obstructions into the air flow path. The balljoint 310 has a hole 312 formed radially about a portion of thecircumference of the ball joint 310. The ball joint 310 has an exhaustport 314 formed in the circumference of the ball joint 310 and directedradially away from the center of the ball joint 310. The exhaust port314 and the hole 312 are located around the circumference of the balljoint 310. As such, the ball joint 312 defines an airflow path throughthe body thereof, with the hole 312 and the exhaust port 314 beingdefined, respectively, as the inlet and the outlet of the airflow paththrough the ball joint 310. The cross-sectional area of the hole 312 hasa size to provide sufficient air flow across the heatsink 220 of theluminaire 200 to sufficiently cool the LED 232. In the embodiment shown,the hole 312 and the exhaust port 314 are formed such that they arelocated substantially diametrically opposite each other about thecircumference of the ball joint 310. The ball joint 310 has locatingfeatures 317 formed therein and/or thereon that define a range of rotarymovement of the luminaire housing 210 and the ball joint 310 relative toeach other. This range of rotary movement defined by the locatingfeatures 317 is such that the hole 312 remains positioned internal tothe luminaire housing 210 at all operating positions of the luminaire200 relative to the headband 100 to avoid creating an unwanted air inletin the luminaire housing 210 upstream of the heatsink 220. Similarly,the lateral sides 315 of the ball joint 310 can be solid or be sealedwith a gasket to prevent any air leakage into and/or out of the ductsystem 300. In some embodiments, such as is shown in FIG. 12, the hole312 comprises two discrete holes 312, one hole 312 being formed in eachside of the two half-members 311 of the ball joint 10

The ball joint 310 is lockingly connected at the exhaust port 314thereof to a flexible duct 320 that can have, for example, a corrugatedconstruction that allows for bending deflections as well as elongationsor contractions thereof when the position of the luminaire 200 relativeto the headband 100 is changed (e.g., by adjusting the position of themechanical linkage 350). The exhaust port 314 of the ball joint 310comprises, in the embodiment shown, a snapping interlock system 318 toensure sufficient mechanical interlocking between the exhaust port 314and the flexible duct 320. The flexible duct 320 is connected at adistal end thereof to a rigid duct 330 attached to the upper housing 400on the top strap of the headband. This rigid duct 330 has, at a distalend thereof from the flexible duct 320, an air moving device 332attached thereto, the outlet of the air moving device 332 being orientedto blow out from a hot air exhaust 420. The luminaire housing 210 has atleast two air inlets 212 formed therein (e.g., integrally) at locationsconfigured to draw ambient air across the heatsink 220. The air movingdevice 332 can be of any suitable type, including a fan, blower,piezoelectric device, or the like.

A sensor is provided to monitor a temperature of the LED, eitherdirectly or indirectly, and a controller is provided to thermostaticallycontrol the air moving device 332 to maintain the temperature of the LED232 within a prescribed operating temperature range. In examples ofindirect thermal management, the temperature of a substrate to which theLED 232 may be attached and/or mounted, the heatsink 220, and/or the airflow passing through the duct system 300 may be monitored, preferably inconjunction with the operational state (e.g., as a percentage of maximumair flow) of the air moving device 332. Gaskets 335 are provided on theinlet and/or the outlet faces of the air moving device 332 to preventintroducing leakage paths within the duct system 300.

In some embodiments, the ball joint 310 comprises two half-members 311ultrasonically welded together to form the body of the ball joint 310,which is held in place within an end of the luminaire housing 210sealingly clamped between flanges thereof, which may, in someembodiments, itself be ultrasonically welded together from separate anddiscrete housing members 210A/210B. This sealing clamping of theluminaire housing 210 about the ball joint 310 can, in some embodiments,be achieved by placing one or more gaskets circumferentially between theball joint-luminaire housing interface being sealed. In some suchembodiments, the one or more gaskets can be installed within a grooveformed in a surface of the ball joint 310, the luminaire housing 210, orboth. The two half-members 311 have a central cavity, generallydesignated 313, formed therein when assembled together. In theembodiment shown, the ball joint 310 sits loosely (e.g., sufficientlyloose to allow the pivoting motion of the luminaire housing 210 relativeto the ball join 310) at the proximal end (relative to the headpiece) ofthe luminaire housing 210, with O-ring gaskets being provided in arecess around central protrusion 316 to produce an air tight interfacebetween the ball joint 310 and the luminaire housing 210 to minimizeleakage paths in the airflow path. As shown, the ball joint 310 canpivot freely within the proximal end of the luminaire housing 210 over arange of motion as determined by the vertical position of both theluminaire 200 and any accompanying downstream exhaust components (e.g.,the flexible duct 320, the rigid duct 330, etc.). The housing 210 isconnected to the mechanical linkage 350 at mounting tab 214.

As such, a method of cooling a luminaire 200 of a head wearable device 1is provided. The method comprises providing an LED 232 within aluminaire housing 210, forming at least one air inlet 212 in theluminaire housing 210, attaching a heatsink 220, directly or indirectly(e.g., via a substrate) to the LED 232, arranging the heatsink 220adjacent the at least one air inlet 212 of the luminaire housing 210,connecting the luminaire housing 210 to the ball joint 310, forming ahole 312 and an exhaust port 314 in the ball joint 310, connecting afirst end of the flexible duct 320 to the ball joint 310 at the exhaustport 314, connecting a rigid duct 330 to the flexible duct 320 at thesecond end of the flexible duct 320, installing the air moving device332 within a hot air exhaust 420 of the upper housing 400, monitoringthe temperature of the LED 232 within the luminaire 200, and controllingthe air moving device 332 to produce an air flow from the at least oneinlet 212 in the luminaire housing 210, through the heatsink 220,through the ball joint 310, through the flexible duct 320, through therigid duct 330, through the air moving device 332, and exhausted fromthe hot air exhaust 420 formed in the upper housing 400, which isattached to a top strap 110 of a headband 100 of the head wearabledevice 1.

Power can be provided to the head wearable device 1 via a power cord 602attached to the upper housing 400. In some embodiments, the power cord602 is of a twist-lock type, such that power cannot be accidentallydisconnected from the head wearable device 1 merely by pulling the powercord 602 out of the holster 600 without an accompanying twisting motionat the connector interface. The power cord 602 may be connected to aholster 600 that is wearably attached to a wearer of the head wearabledevice 1. In some embodiments, the holster 600 is configured to have oneor more battery packs installed therein, which allows the wearer of thehead wearable device 1 unrestricted movement. In some embodiments, theholster 600 is configured to be connected to a substantially continuouspower source (e.g., a wall electrical outlet) for substantiallyindefinite operation. The holster 600 comprises an intensity control(e.g., a rotary control knob) that regulates power to the LED 232 fromeither battery or the direct power supply and controls the intensityemitted from the LED 232 and, consequently, also from the luminaire 200.

The luminaire 200 is configured to produce a pure white light outputwithout a yellow ring being present around the perimeter of the lightoutput area. Apertures may be used in optical devices such as camerasand telescopes to limit light entering the device. Such apertures may bemanufactured from any suitable material, including from a thin metal andmay, in some aspects, advantageously be either anodized black or paintedblack to minimize unwanted reflections within the optical path. It isknown that such apertures may be suspended mechanically within the lenscell in any manner and orientation, as dictated by the optical designand subsequent testing iterations. The presently disclosed luminaire 200is thus configured to restrict unwanted stray light (aberrations) fromexiting the optical path, thereby ensuring a near ideal white-spotpresentation. It is known that aberrations in the spot presentation canresult from light scattering in the optical train due to source lightreflections off of internal mechanical components, LED “yellow lightphenomenon,” and the like. It is advantageous to ensure that the opticaltrain will yield a substantially homogeneous white-spot presentation.The presently disclosed embodiment optimizes the projection of whitelight while helping to restrict both stray light reflections and yellowlight from exiting the optical path. As shown, the light projectingportion of the luminaire 200 is configured to produce a white-spotpresentation having an adjustable focal point and/or focal length,thereby allowing for a white-spot presentation having an adjustable size(e.g., diameter). The focal length and spotlight size is adjustable byturning the adjustment knob 202 (see FIG. 12) provided on the luminaire200. The outer lens 206 is contained within an outer lens structure,generally 204, at the outlet of the optical train.

FIG. 17 is a partially exploded view of the head wearable device 1,showing the attachment of the luminaire 200, via the mechanical linkage350, to the headband 100 and the flexible duct 320 to the rigid duct330. FIG. 18 is a partially exploded view of the components of the depthadjuster 450 for the position of the strap 152 of the occipital basket150 relative to the upper housing 410 attached to the top strap 110 ofthe headband 100. In some embodiments, the occipital basket 150 ispivotable to better adjust to the head shape of the wearer. The depthadjuster 450 shown in FIG. 18 comprises a gear 470 that engages withteeth 156 (see FIGS. 13-15) formed on the inner surface of the slot 154(see FIGS. 13-15) of the strap 152 that is being positionally adjustedrelative to the upper housing 400 and the top strap 110. The gear 470projects through the upper housing 400 and is fixedly and rotationallycoupled to an adjustment knob 460. The adjustment knob 460 is rotatablylocked to the gear 470 by connector plate 462 and screw 472. A coverplate 464 is attached to the adjustment knob 460, but in someembodiments the cover plate 464 can be integrally formed as theadjustment knob 460. As such, a rotary movement of the knob 460 causes acorresponding rotary movement of the gear 470 and a correspondinglengthening or shortening of the strap 152 which engages with the gear470. FIG. 19 is a partially exploded view of the components of theheadband adjuster 700 for the circumference of the head wearable device1. The headband adjuster 700 shown in FIG. 19 is largely similar to thedepth adjuster shown in FIG. 18, but the rear housing comprises atwo-part rear housing that has a base 710 that allows for visualizationof the engagement of the teeth 134A/134B of the lateral extension straps130A/130B with the gear 730 when assembling the head wearable device 1.This visualization internal to the headband adjuster 700 ensures thatthe lateral extension straps 130A/130B are each equally engaged aroundthe gear 730 so the components of the head wearable device 1 aresymmetrical about a vertical plane arranged along the longitudinal axisof the head wearable device 1. The headband adjuster 700 furthercomprises a cover panel 720 that engages at least partially over thebase 710 to obscure the engagement of the gear 730 with the lateralextension straps 130A/130B during normal operation of the head wearabledevice 1. The gear 730 projects through a hole formed in the occipitalbasket 150 and the base 710 is secured to the occipital basket 150 at apredetermined mounting point, for example, by screws 722. The gear 730is then fixedly and rotationally coupled to an adjustment knob 740 byscrew 732, which passes through the occipital basket 150. The adjustmentknob 460 is rotatably locked to the gear 730 by connector plate 742 andscrew 732. A cover plate 744 is attached to the adjustment knob 740, butin some embodiments the cover plate 744 can be integrally formed as theadjustment knob 740. As such, a rotary movement of the adjustment knob740 causes a corresponding rotary movement of the gear 730 and acorresponding lengthening or shortening of the circumference of the headwearable device 1.

A method of adjusting a size of a headpiece of a head wearable device toa head size of a wearer, the headpiece comprising a headband 100 and anoccipital basket 150, is provided. The method comprises attaching anupper housing 400 to an external surface of a top strap 110 of theheadband 100; inserting a strap 152 of the occipital basket 150 at leastpartially into the upper housing 400; engaging a first gear 470 with aplurality of teeth 156 formed in a slot 154, which is longitudinallyoriented along a length of the strap 152 of the occipital basket 150;turning a first adjustment knob 460, which is rotationally locked to thefirst adjustment gear 470, to adjust a depth of the headpiece; attachinga second housing to an external surface of the occipital basket 150;inserting an end of at least two lateral extension straps 130A/130B intothe second housing, with the end of a first lateral extension strap 130Abeing inserted from an opposite end of the housing from the end of asecond lateral extension strap 130B, wherein the two lateral extensionstraps 130A/130B are hingedly attached to lateral straps 120A/120B ofthe headband 100 to define a circumference of the headpiece; engaging asecond gear 730 with a plurality of teeth 134A/134B formed in a slot132A/132B of each of the lateral extension straps 130A/130B such thatthe second gear 730 is engaged with both of the lateral extension straps130A/130B; and turning a second adjustment knob 740, which isrotationally locked to the second adjustment gear 730, to adjust acircumference of the headpiece.

In some embodiments, the method comprises providing a first visual indexalong a length of the strap 152 of the occipital basket 150, the firstvisual index 157 comprising sequential alphanumeric characters todesignate predetermined depth settings for the headpiece; providing asecond visual index 136 along a length of at least one of the lateralextension straps 130A/130B, the second visual index 136 comprisingsequential alphanumeric characters to designate predeterminedcircumference settings for the head wearable device 1; determining awearer preference for the depth and circumference of the head wearabledevice corresponding to the first and second visual indexes 157/136;placing the head wearable device 1 on the wearer's head; adjusting thefirst adjustment knob 460 such that the first visual index 157 indicatesthat the wearer preference for the depth of the head wearable device 1has been achieved; and adjusting the second adjustment knob 730 suchthat the second visual index 136 indicates that the wearer preferencefor the circumference of the head wearable device 1 has been achieved.

In some aspects, a head wearable device comprises a headpiece; a housingattached to the headpiece; a luminaire attached to the headpiece, theluminaire comprising a luminaire housing and at least one light sourcelocated within the luminaire housing; a duct system connecting theluminaire to the housing; a ball joint rotatably connecting the ductsystem to the luminaire; and an air moving device configured to induce acooling air flow through an inlet in the luminaire housing, through theheatsink, through the ball joint, through the duct system, and out of anexhaust in the housing on the top surface of the headpiece. In someembodiments of the head wearable device, the housing is attached to atop surface of the headpiece In some embodiments, the head wearabledevice comprises a controller configured to monitor a temperature of theat least one light source and to modulate an operational setting of theair moving device to maintain the temperature of the at least one lightsource within a predetermined operating range. In some embodiments ofthe head wearable device, the headpiece comprises a headband, which hasat least a top strap and two lateral straps, and an occipital basket,wherein the headband is connected to the occipital basket and theheadband and the occipital basket are independently adjustable relativeto each other. In some embodiments of the head wearable device, the atleast one light source comprises a light emitting diode (LED). In someembodiments of the head wearable device, the ball joint is pivotablyand/or swivelably connected to the luminaire. In some embodiments of thehead wearable device, the duct system comprises a flexible ductconnected to a rigid duct. In some embodiments of the head wearabledevice, the air moving device is positioned inside the housing, withinthe rigid duct, in a position adjacent to the exhaust in the housing. Insome embodiments of the head wearable device, the luminaire is attachedto the headpiece by a mechanical linkage such that an angle and/orposition of the luminaire relative to the headpiece is adjustable. Insome embodiments of the head wearable device, the flexible ductcomprises a corrugated construction such that a length thereof can beshortened or lengthened as the angle and/or position of the luminairerelative to the headpiece is adjusted. In some embodiments of the headwearable device, the ball joint defines a range of angular motion forthe luminaire and comprises a passage and an exhaust port formed in acircumferential wall of the ball joint, the range of angular motionbeing such that the passage remains in a position to provide an air flowpath from the luminaire housing into the ball joint. In some embodimentsof the head wearable device, the passage and the exhaust port arearranged on substantially opposite sides of the ball joint. In someembodiments of the head wearable device, the passage is not externallyvisible from the luminaire housing at any point along the range ofangular motion. In some embodiments, the head wearable device comprisesa heatsink located within the luminaire housing. In some embodiments ofthe head wearable device, the luminaire is configured to optimize aprojection of white light and restrict both stray light reflections andyellow light from exiting the lens cell. In some embodiments of the headwearable device, the lens cell is configured to produce a substantiallyhomogeneous white-spot presentation. In some embodiments of the headwearable device, the lens cell comprises an adjustable focal lengthand/or focal point. In some embodiments, the head wearable devicecomprises a power cord attached to the upper housing attached to the topstrap of the headband, the power cord being configured to receive powerfrom a holster. In some embodiments of the head wearable device, thepower is provided from a rechargeable battery or a continuous powersource, and wherein the holster is configured to adjust an intensity oflight output from the at least one light source.

In some aspects, a head wearable device comprises a headpiececomprising: a headband comprising a top strap and at least two lateralstraps; an occipital basket comprising a strap, the occipital basketbeing attached to the headband by at least one lateral extension strappivotably attached by a hinge to a distal end of each respective lateralstrap of the headband; a first housing attached to an outer surface ofthe top strap of the headband; a depth adjuster attached to the firsthousing, the depth adjuster comprising a first gear rotatably fixed to afirst knob; wherein the strap of the occipital basket comprises a slotwith a plurality of teeth formed around a longitudinal edge of the slot;wherein the first gear is captively held within the slot and engageswith the plurality of teeth; wherein the depth adjuster is configuredsuch that a rotary movement of the first gear causes a longitudinalmovement of the strap of the occipital basket to change a distancebetween the occipital basket and the first housing; wherein a depth ofthe headpiece changes when the distance between the occipital basket andthe first housing changes, or increases or decreases; and wherein thestrap comprises a first visual index comprising a first plurality ofsequential characters, each of which correspond to one of a plurality ofpredetermined depth settings of the headpiece; and a second housingattached to an outer surface of the occipital basket; a headbandadjuster at an outer surface of the occipital basket, the headbandadjuster comprising a second gear rotatably fixed to a second knob;wherein the lateral extension straps each comprise a slot with aplurality of teeth formed around a longitudinal edge of the slot;wherein the second gear is captively held within the slot of eachlateral extension strap and engages with the plurality of teeth of eachof the lateral extension straps; wherein the headband adjuster isconfigured such that a rotary movement of the second gear causes alongitudinal movement of the lateral extension straps to change acircumference of the headpiece; and wherein at least one of the lateralextension straps comprises a second visual index comprising a secondplurality of sequential characters, each of which correspond to one of aplurality of predetermined circumferential settings of the headpiece;wherein the head wearable device is configured such that the lateralextension straps rotate about the hinge, relative to the lateral strapsas the depth of the headpiece changes. In some embodiments of the headwearable device, the first and second visual indexes comprisealphanumeric characters. In some embodiments of the head wearabledevice, the first visual index and the second visual index comprisedifferent ranges and/or types of alphanumeric characters. In someembodiments of the head wearable device, the first visual indexcomprises a plurality of sequential letters and the second visual indexcomprises a plurality of sequential numbers. In some embodiments of thehead wearable device, the first visual index comprises a plurality ofsequential numbers and the second visual index comprises a plurality ofsequential letters. In some embodiments, the head wearable devicecomprises padding on an inner surface of the headband and the occipitalbasket. In some embodiments of the head wearable device, a notch isformed into a lower edge of the occipital basket to prevent a wearer'shair from interfering with proper fitment of the headpiece about a headof a wearer. In some embodiments of the head wearable device, thepadding on the occipital basket comprises a recessed area to prevent thewearer's hair from interfering with proper fitment of the headpieceabout the head of the wearer. In some embodiments of the head wearabledevice, the padding is removably attached to the headband and theoccipital basket. In some embodiments of the head wearable device, thepadding is spaced apart from a surface of a head of a wearer of the headwearable device at a suture between adjacent plates of a skull of thewearer of the head wearable device.

In some aspects, a method of adjusting a size of a headpiece of a headwearable device to a head size of a wearer is provided, the headpiececomprising a headband and an occipital basket, and the method comprisingattaching a first housing to an external surface of a top strap of theheadband; inserting a strap of the occipital basket at least partiallyinto the first housing; engaging a first gear with a plurality of teethformed in a slot, which is longitudinally oriented along a length of thestrap of the occipital basket; turning a first knob, which isrotationally locked to the first gear, to adjust a depth of theheadpiece; attaching a second housing to an external surface of theoccipital basket; inserting an end of at least two lateral extensionstraps into the second housing, with the end of a first lateralextension strap being inserted from an opposite end of the housing fromthe end of a second lateral extension strap, wherein the two lateralextension straps are hingedly attached to lateral straps of the headbandto define a circumference of the headpiece; engaging a second gear witha plurality of teeth formed in a slot of each of the lateral extensionstraps such that the second gear is engaged with both of the lateralextension straps; and turning a second knob, which is rotationallylocked to the second gear, to adjust a circumference of the headpiece.In some embodiments, the method comprises providing a first visual indexalong a length of the strap of the occipital basket, the first visualindex comprising sequential alphanumeric characters to designatepredetermined depth settings for the headpiece; providing a secondvisual index along a length of at least one of the lateral extensionstraps, the second visual index comprising sequential alphanumericcharacters to designate predetermined circumference settings for theheadpiece; determining a wearer preference for the depth andcircumference of the headpiece corresponding to the first and secondvisual indexes; placing the head wearable device on the wearer's head;adjusting the first knob such that the first visual index indicates thatthe wearer preference for the depth of the headpiece has been achieved;and adjusting the second knob such that the second visual indexindicates that the wearer preference for the circumference of theheadpiece has been achieved. In some embodiments of the method, thefirst visual index and the second visual index comprise different rangesand/or types of alphanumeric characters. In some embodiments of themethod, the first visual index comprises a plurality of sequentialletters, the second visual index comprises a plurality of sequentialnumbers, and the wearer preference is designated by one of the pluralityof sequential letters and one of the plurality of sequential numbers. Insome embodiments of the method, the first visual index comprises aplurality of sequential numbers and the second visual index comprises aplurality of sequential letters. In some embodiments, the methodcomprises attaching padding on an inner surface of the headband and theoccipital basket. In some embodiments, the method comprises forming anotch into a lower edge of the occipital basket to prevent a wearer'shair from interfering with proper fitment of the headpiece about a headof a wearer. In some embodiments, the method comprises forming arecessed area in the padding on the occipital basket to prevent thewearer's hair from interfering with proper fitment of the headpieceabout the head of the wearer. In some embodiments of the method, thepadding is removably attached to the headband and the occipital basket.In some embodiments, the method comprises spacing the padding apart froma surface of a head of a wearer of the head wearable device at a suturebetween adjacent plates of a skull of the wearer of the head wearabledevice.

In some aspects, a headlight device comprises a headband comprising arear portion, a side portion and a top portion, the headband having aninner surface; a padding system comprising: a rear pad attached to theinner surface of the rear portion of the headband; a side pad attachedto the inner surface of the side portion of the headband; a top padattached to the inner surface of the top portion of the headband; and,optionally, a brow pad attached to the inner surface of the headbandabout an intersection of the top portion and the side portion; whereinat least one of the rear pad and the brow pad comprises a first layer ofa first cushioning material having a first durometer, and a second layerof a second cushioning material having a second durometer that is harderthan the first durometer. In some embodiments of the headlight device,the first cushioning material is silicone foam having a first durometer,and the second cushioning material is silicone foam having a seconddurometer that is harder than the first durometer. In some embodimentsof the headlight device, the second layer of the second cushioningmaterial is closer than the first layer of the first cushioning materialto the inner surface of the rear portion of the headband. In someembodiments of the headlight device, the first layer of the firstcushioning material and the second layer of the second cushioningmaterial are each perforated. In some embodiments of the headlightdevice, the majority of the perforations in the first layer of the firstcushioning material are generally circular, and the majority of theperforations in the second layer of the second cushioning material arein a shape other than circular. In some embodiments of the headlightdevice, the perforations in the second layer of the second cushioningmaterial are generally square or rectangular, or generally in agrid-like pattern. In some embodiments of the headlight device, thesecond layer of the second cushioning material has more open space onits upper or lower surface due to perforations than the first layer ofthe first cushioning material. In some embodiments of the headlightdevice, the total volume of cavity due to perforations in the secondlayer of the second cushioning material is higher than the total volumeof cavity in the first layer of the first cushioning material. In someembodiments of the headlight device, the rear pad has an inner surfacein contact with an wearer and an outer surface attached to the innersurface of the rear portion of the headband, and the rear pad comprisesa recess on its inner surface. In some embodiments of the headlightdevice, at least one of the top pad and the side pad comprises urethanefoam and forms segments. In some embodiments of the headlight device, atleast one of the top pad, the side pad, and the rear pad is spaced apartfrom a surface of a head of a wearer of the head wearable device at asuture between adjacent plates of a skull of the wearer of the headwearable device. In some embodiments of the headlight device, the firstcushioning material comprises an extra firm silicone foam, the firstdurometer of which has a compression force deflection in a range of16-26 pounds per square inch (psi), and wherein the second cushioningmaterial comprises a different silicone foam, the second durometer ofwhich has a compression force deflection in a range of 1-20 psi. In someembodiments of the headlight device, the first cushioning materialcomprises a firm silicone foam, the first durometer of which has acompression force deflection in a range of 12-20 pounds per square inch(psi), and wherein the second cushioning material comprises a differentsilicone foam, the second durometer of which has a compression forcedeflection in a range of 1-14 or 16-26 psi. In some embodiments of theheadlight device, the first cushioning material comprises a mediumsilicone foam, the first durometer of which has a compression forcedeflection in a range of 6-14 pounds per square inch (psi), and whereinthe second cushioning material comprises a different silicone foam, thesecond durometer of which has a compression force deflection in a rangeof 1-7 or 12-26 psi. In some embodiments of the headlight device, thefirst cushioning material comprises a firm silicone foam, the firstdurometer of which has a compression force deflection in a range of 2-7pounds per square inch (psi), and wherein the second cushioning materialcomprises a different silicone foam, the second durometer of which has acompression force deflection in a range of 1-5 or 6-26 psi. In someembodiments of the headlight device, the first cushioning materialcomprises a firm silicone foam, the first durometer of which has acompression force deflection in a range of 1-5 pounds per square inch(psi), and wherein the second cushioning material comprises a differentsilicone foam, the second durometer of which has a compression forcedeflection in a range of about 1.5 or 2-26 psi. In some embodiments ofthe headlight device, the first cushioning material comprises a firmsilicone foam, the first durometer of which has a compression forcedeflection of about 1.5 pounds per square inch (psi), and wherein thesecond cushioning material comprises a different silicone foam, thesecond durometer of which has a compression force deflection in a rangeof 1-26 psi.

In some aspects, a headlight device comprises a headband for encirclingthe head of a wearer; a padding system comprising a pad removablyattached to at least a portion of the headband; wherein the padcomprises a first layer of a first cushioning material having a firstdurometer, and a second layer of a second cushioning material having asecond durometer that is harder than the first durometer; and whereinthe first layer is perforated in a first perforation pattern, and thesecond layer is perforated in a second perforation pattern that differsfrom the first perforation pattern. In some embodiments of the headlightdevice, the first layer of the first cushioning material is a layer ofsilicone foam having a first durometer, and the second layer of thesecond cushioning material is a layer of silicone foam having a seconddurometer that is harder than the first durometer. In some embodimentsof the headlight device, the second layer of the second cushioningmaterial is closer than the first layer of the first cushioning materialto the inner surface of the rear portion of the headband. In someembodiments of the headlight device, the majority of the perforations inone of the first and second layers are circular, and the majority of theperforations in the other layer are in a shape other than circular. Insome embodiments of the headlight device, the perforations in the otherlayer are generally square or rectangular or generally in a grid-likepattern. In some embodiments of the headlight device, the second layerof the second cushioning material has more open space on its upper orlower surface due to perforations than the first layer of the firstcushioning material. In some embodiments of the headlight device, thetotal volume of cavity due to perforations in the second layer of thesecond cushioning material is higher than the total volume of cavity inthe first layer of the first cushioning material. In some embodiments ofthe headlight device, the pad is spaced apart from a surface of a headof a wearer of the head wearable device at a suture between adjacentplates of a skull of the wearer of the head wearable device. In someembodiments of the headlight device, the first cushioning materialcomprises an extra firm silicone foam, the first durometer of which hasa compression force deflection in a range of 16-26 pounds per squareinch (psi), and wherein the second cushioning material comprises adifferent silicone foam, the second durometer of which has a compressionforce deflection in a range of 1-20 psi. In some embodiments of theheadlight device, the first cushioning material comprises a firmsilicone foam, the first durometer of which has a compression forcedeflection in a range of 12-20 pounds per square inch (psi), and whereinthe second cushioning material comprises a different silicone foam, thesecond durometer of which has a compression force deflection in a rangeof 1-14 or 16-26 psi. In some embodiments of the headlight device, thefirst cushioning material comprises a medium silicone foam, the firstdurometer of which has a compression force deflection in a range of 6-14pounds per square inch (psi), and wherein the second cushioning materialcomprises a different silicone foam, the second durometer of which has acompression force deflection in a range of 1-7 or 12-26 psi. In someembodiments of the headlight device, the first cushioning materialcomprises a firm silicone foam, the first durometer of which has acompression force deflection in a range of 2-7 pounds per square inch(psi), and wherein the second cushioning material comprises a differentsilicone foam, the second durometer of which has a compression forcedeflection in a range of 1-5 or 6-26 psi. In some embodiments of theheadlight device, the first cushioning material comprises a firmsilicone foam, the first durometer of which has a compression forcedeflection in a range of 1-5 pounds per square inch (psi), and whereinthe second cushioning material comprises a different silicone foam, thesecond durometer of which has a compression force deflection in a rangeof about 1.5 or 2-26 psi. In some embodiments of the headlight device,the first cushioning material comprises a firm silicone foam, the firstdurometer of which has a compression force deflection of about 1.5pounds per square inch (psi), and wherein the second cushioning materialcomprises a different silicone foam, the second durometer of which has acompression force deflection in a range of 1-26 psi.

In some aspects, a method is provided of cooling a luminaire of a headwearable device comprises providing an LED within a luminaire housing;forming at least one air inlet in the luminaire housing; attaching aheatsink to a substrate to which the LED is mounted; arranging theheatsink adjacent the at least one air inlet of the luminaire housing;connecting the luminaire housing to a ball joint; forming a hole and anexhaust port in the ball joint; connecting a first end of the flexibleduct to the ball joint at the exhaust port; connecting a rigid duct tothe flexible duct at the second end of the flexible duct; installing theair moving device within a hot air exhaust of the upper housing;monitoring the temperature of the LED within the luminaire; andcontrolling the air moving device to produce an air flow to cool theLED. In some embodiments, the method comprises attaching the upperhousing to a top surface of a headpiece of the head wearable device. Insome embodiments, the method comprises attaching a power cord to theupper housing to receive power from a holster. In some embodiments, themethod comprises adjusting an intensity of light output from the atleast one light source via the holster, wherein the power comprises arechargeable battery or a continuous power source. In some embodimentsof the method, the headpiece comprises a headband, which has at least atop strap and two lateral straps, and an occipital basket, wherein theheadband is connected to the occipital basket and the headband and theoccipital basket are independently adjustable relative to each other. Insome embodiments, the method comprises attaching the luminaire to theheadpiece via a mechanical linkage, such that an angle and/or positionof the luminaire relative to the headpiece is adjustable. In someembodiments of the method, the flexible duct comprises a corrugatedconstruction such that a length thereof can be shortened or lengthenedas the angle and/or position of the luminaire relative to the headpieceis adjusted. In some embodiments, the method comprises monitoring, via acontroller, a temperature of the at least one light source andmodulating an operational setting of the air moving device to maintainthe temperature of the at least one light source within a predeterminedoperating range. In some embodiments of the method, the at least onelight source comprises a light emitting diode (LED). In some embodimentsof the method, connecting the luminaire housing to the ball jointcomprises a pivotable and/or swivelable connection. In some embodiments,the method comprises defining, via the ball joint, a range of angularmotion for the luminaire and comprises a passage and an exhaust portformed in a circumferential wall of the ball joint, wherein the range ofangular motion is such that the passage remains in a position to providean air flow path from the luminaire housing into the ball joint. In someembodiments, the method comprises arranging the passage and the exhaustport on substantially opposite sides of the ball joint. In someembodiments of the method, the passage is not externally visible fromthe luminaire housing at any point along the range of angular motion. Insome embodiments, the method comprises arranging a heatsink within theluminaire housing. In some embodiments, the method comprises optimizinga projection of white light and restricting both stray light reflectionsand yellow light from exiting the lens cell. In some embodiments, themethod comprises producing, via the lens cell, a substantiallyhomogeneous white-spot presentation. In some embodiments of the method,the lens cell comprises an adjustable focal length and/or focal point.

In some further aspects, a headlight device is provided, the headlightdevice comprising: a headband for encircling the head of a wearer; apadding system comprising a rear pad removably attached to at least aportion of the headband; wherein the rear pad comprises a first layer ofa first cushioning material having a first durometer, and a second layerof a second cushioning material having a second durometer that isdifferent from the first durometer; wherein the first layer isperforated in a first perforation pattern, and the second layer isperforated in a second perforation pattern that differs from the firstperforation pattern; wherein the first layer comprises an inner surfacein contact with a wearer; wherein the second layer comprises an outersurface attached to the inner surface of the rear portion of theheadband; and wherein the rear pad comprises a recess on an innersurface thereof.

While the embodiments disclosed herein are provided merely for purposesof illustration, the features included in each of these embodiments maybe combined in any possible combination, as would be readily understoodby those having ordinary skill in the art.

While at least one example embodiment of the invention(s) is disclosedherein, it should be understood that modifications, substitutions andalternatives may be apparent to one of ordinary skill in the art and canbe made without departing from the scope of this disclosure. Thisdisclosure is intended to cover any adaptations or variations of theexample embodiment(s). In addition, in this disclosure, the terms“comprise” or “comprising” do not exclude other elements or steps, theterms “a”, “an” or “one” do not exclude a plural number, and the term“or” means either or both. Furthermore, characteristics or steps whichhave been described may also be used in combination with othercharacteristics or steps and in any order unless the disclosure orcontext suggests otherwise.

1. A headlight device comprising: a headband comprising a rear portion,a side portion and a top portion, the headband having an inner surface;and a padding system comprising: a rear pad attached to the innersurface of the rear portion of the headband; a side pad attached to theinner surface of the side portion of the headband; a top pad attached tothe inner surface of the top portion of the headband; and a brow padattached to the inner surface of the headband about an intersection ofthe top portion and the side portion; wherein at least one of the rearpad and the brow pad comprises a first layer of a first cushioningmaterial having a first durometer, and a second layer of a secondcushioning material having a second durometer that is different from thefirst durometer.
 2. The headlight device of claim 1, wherein the firstcushioning material comprises silicone foam, the first durometer ofwhich has a compression force deflection of about 1.5 pounds per squareinch (psi), and wherein the second cushioning material comprisessilicone foam, the second durometer of which has a compression forcedeflection of about 6-14 psi.
 3. The headlight device of claim 1,wherein the first cushioning material comprises an extra firm siliconefoam, the first durometer of which has a compression force deflection ina range of 16-26 pounds per square inch (psi), and wherein the secondcushioning material comprises a different silicone foam, the seconddurometer of which has a compression force deflection in a range of 1-20psi.
 4. The headlight device of claim 1, wherein the first cushioningmaterial comprises a firm silicone foam, the first durometer of whichhas a compression force deflection in a range of 12-20 pounds per squareinch (psi), and wherein the second cushioning material comprises adifferent silicone foam, the second durometer of which has a compressionforce deflection in a range of 1-14 or 16-26 psi.
 5. The headlightdevice of claim 1, wherein the first cushioning material comprises amedium silicone foam, the first durometer of which has a compressionforce deflection in a range of 6-14 pounds per square inch (psi), andwherein the second cushioning material comprises a different siliconefoam, the second durometer of which has a compression force deflectionin a range of 1-7 or 12-26 psi.
 6. The headlight device of claim 1,wherein the first cushioning material comprises a firm silicone foam,the first durometer of which has a compression force deflection in arange of 2-7 pounds per square inch (psi), and wherein the secondcushioning material comprises a different silicone foam, the seconddurometer of which has a compression force deflection in a range of 1-5or 6-26 psi.
 7. The headlight device of claim 1, wherein the firstcushioning material comprises a firm silicone foam, the first durometerof which has a compression force deflection in a range of 1-5 pounds persquare inch (psi), and wherein the second cushioning material comprisesa different silicone foam, the second durometer of which has acompression force deflection in a range of about 1.5 or 2-26 psi.
 8. Theheadlight device of claim 1, wherein the first cushioning materialcomprises a firm silicone foam, the first durometer of which has acompression force deflection of about 1.5 pounds per square inch (psi),and wherein the second cushioning material comprises a differentsilicone foam, the second durometer of which has a compression forcedeflection in a range of 1-26 psi.
 9. The headlight device of claim 1,wherein the second layer of the second cushioning material is closerthan the first layer of the first cushioning material to the innersurface of the rear portion of the headband.
 10. The headlight device ofclaim 1, wherein the first layer of the first cushioning material andthe second layer of the second cushioning material are each perforated.11. The headlight device of claim 10, wherein a majority of theperforations in the first layer of the first cushioning material aregenerally circular, and a majority of the perforations in the secondlayer of the second cushioning material are in a shape other thancircular.
 12. The headlight device of claim 11, wherein the perforationsin the second layer of the second cushioning material are generallysquare or rectangular, or generally in a grid-like pattern.
 13. Theheadlight device of claim 10, wherein the second layer of the secondcushioning material has more open space on its upper or lower surfacedue to perforations than the first layer of the first cushioningmaterial.
 14. The headlight device of claim 10, wherein a total volumeof cavity due to perforations in the second layer of the secondcushioning material is higher than a total volume of cavity in the firstlayer of the first cushioning material.
 15. The headlight device ofclaim 1, wherein the rear pad has an inner surface in contact with awearer and an outer surface attached to the inner surface of the rearportion of the headband, and the rear pad comprises a recess on itsinner surface.
 16. The headlight device of claim 1, wherein at least oneof the top pad and the side pad comprises urethane foam and formssegments.
 17. The headlight device of claim 1, wherein at least one ofthe top pad, the side pad, and the rear pad is configured to bepositioned on a head of a wearer of the head wearable device withoutbeing disposed over a suture between adjacent plates of a skull of thewearer of the head wearable device.
 18. A headlight device comprising: aheadband for encircling the head of a wearer; a padding systemcomprising a pad removably attached to at least a portion of theheadband; wherein the pad comprises a first layer of a first cushioningmaterial having a first durometer, and a second layer of a secondcushioning material having a second durometer that is different from thefirst durometer; and wherein the first layer is perforated in a firstperforation pattern, and the second layer is perforated in a secondperforation pattern that differs from the first perforation pattern. 19.The headlight device of claim 18, wherein the first layer of the firstcushioning material comprises a layer of silicone foam, the firstdurometer of which has a compression force deflection of about 1.5pounds per square inch (psi), and wherein the second layer of the secondcushioning material comprises a layer of silicone foam, the seconddurometer of which has a compression force deflection of about 6-14 psi.20. The headlight device of claim 18, wherein the first cushioningmaterial comprises an extra firm silicone foam, the first durometer ofwhich has a compression force deflection in a range of 16-26 pounds persquare inch (psi), and wherein the second cushioning material comprisesa different silicone foam, the second durometer of which has acompression force deflection in a range of 1-20 psi.
 21. The headlightdevice of claim 18, wherein the first cushioning material comprises afirm silicone foam, the first durometer of which has a compression forcedeflection in a range of 12-20 pounds per square inch (psi), and whereinthe second cushioning material comprises a different silicone foam, thesecond durometer of which has a compression force deflection in a rangeof 1-14 or 16-26 psi.
 22. The headlight device of claim 18, wherein thefirst cushioning material comprises a medium silicone foam, the firstdurometer of which has a compression force deflection in a range of 6-14pounds per square inch (psi), and wherein the second cushioning materialcomprises a different silicone foam, the second durometer of which has acompression force deflection in a range of 1-7 or 12-26 psi.
 23. Theheadlight device of claim 18, wherein the first cushioning materialcomprises a firm silicone foam, the first durometer of which has acompression force deflection in a range of 2-7 pounds per square inch(psi), and wherein the second cushioning material comprises a differentsilicone foam, the second durometer of which has a compression forcedeflection in a range of 1-5 or 6-26 psi.
 24. The headlight device ofclaim 1, wherein the first cushioning material comprises a firm siliconefoam, the first durometer of which has a compression force deflection ina range of 1-5 pounds per square inch (psi), and wherein the secondcushioning material comprises a different silicone foam, the seconddurometer of which has a compression force deflection in a range ofabout 1.5 or 2-26 psi.
 25. The headlight device of claim 18, wherein thefirst cushioning material comprises a firm silicone foam, the firstdurometer of which has a compression force deflection of about 1.5pounds per square inch (psi), and wherein the second cushioning materialcomprises a different silicone foam, the second durometer of which has acompression force deflection in a range of 1-26 psi.
 26. The headlightdevice of claim 18, wherein the second layer of the second cushioningmaterial is closer than the first layer of the first cushioning materialto the inner surface of the rear portion of the headband.
 27. Theheadlight device of claim 18, wherein a majority of the perforations inone of the first and second layers are circular, and a majority of theperforations in another of the first and second layers are in a shapeother than circular.
 28. The headlight device of claim 27, wherein theperforations in the other layer are generally square or rectangular orgenerally in a grid-like pattern.
 29. The headlight device of claim 18,wherein the second layer of the second cushioning material has more openspace on its upper or lower surface due to perforations than the firstlayer of the first cushioning material.
 30. The headlight device ofclaim 18, wherein a total volume of cavity due to perforations in thesecond layer of the second cushioning material is higher than a totalvolume of cavity in the first layer of the first cushioning material.31. The headlight device of claim 18, wherein the pad is configured tobe positioned on a head of a wearer of the head wearable device withoutbeing disposed over a suture of a skull of the wearer of the headwearable device.
 32. A headlight device comprising: a headband forencircling the head of a wearer; a padding system comprising a rear padremovably attached to at least a portion of the headband; wherein therear pad comprises a first layer of a first cushioning material having afirst durometer, and a second layer of a second cushioning materialhaving a second durometer that is different from the first durometer;wherein the first layer is perforated in a first perforation pattern,and the second layer is perforated in a second perforation pattern thatdiffers from the first perforation pattern; wherein the first layercomprises an inner surface in contact with a wearer; wherein the secondlayer comprises an outer surface attached to the inner surface of therear portion of the headband; and wherein the rear pad comprises arecess on an inner surface thereof.